Method and apparatus for folding a web

ABSTRACT

A web has a series of cut outs that define bridging portions therebetween. A method for folding the web includes providing the web to a first conveyor, folding the web about a folding wheel to define a folded edge that extends through the series of cut outs, transferring the web to a second conveyor having an included angle of 15 to 40 degrees in relation to the first conveyor, folding the web about a folding bar to maintain the folded edge, and spanning at least one cut out with the folding bar and contemporaneously contacting at least two bridge portions with the folding bar to maintain the folded edge of the web about the folding bar as the web passes the folding wheel edge.

This application claims priority as a continuation of application Ser.No. 11/496,131, filed on Jul. 31, 2006. The entirety of application Ser.No. 11/496,131 is incorporated herein by reference,

BACKGROUND OF THE INVENTION

Various methods of folding webs are known in the art. For example,folding boards, folding bars, vacuum folders, and the like, andcombinations thereof have been used in various converting operationssuch as disposable absorbent article manufacturing. However, asdisposable absorbent articles have become more “garment-like” themanufacturing processes, including the folding processes, have becomemore complex. For example, the folding processes may include foldingwebs having multiple layers of material, discrete attachments, cut awayportions, and the like, and combinations thereof. Traditional foldingprocesses are not suited to fold such complex webs. Therefore, thereremains a need for a method and apparatus for folding a complex webduring high-speed converting operations.

SUMMARY OF THE INVENTION

In one aspect, the present invention provides an apparatus for folding aweb. The apparatus includes a first conveyor, a second conveyor in closeproximity to the first conveyor, a folding wheel aligned in closeproximity to both the first and second conveyors, and a folding barextending above and generally parallel with the second conveyor.

In various embodiments, the first and second conveyors may define anincluded angle of 15 to 40 degrees. In various embodiments, theapparatus may further include a folding board located proximate to thesecond conveyor such that the folding bar extends between the foldingboard and the second conveyor. In some embodiments, the folding wheelmay include a shaft and the folding bar may be connected to the shaftand cantilevered over the second conveyor. In some embodiments, thefolding bar may be shaped like the number “7.” In some embodiments, atleast one of the first and second conveyors is a vacuum conveyor.

In another aspect, the present invention provides a method for folding aweb. The method includes providing a web to a first conveyor, passingthe web about a folding wheel to define a folded edge, transferring theweb to a second conveyor, and folding the web about a folding bar tomaintain the folded edge.

In some embodiments, the first conveyor and the second conveyor maydefine an included angle of 15 to 40 degrees. In some embodiments, theweb includes a series of cut outs and the folded edge extends throughthe series of cut outs. The series of cut outs define a series ofbridging portions located between the cut outs. The method furtherincludes spanning at least one cut out with the folding bar andcontacting at least two bridging portions contemporaneously with thefolding bar to maintain the folded edge after the web exits the foldingwheel. The method further includes spanning at least two cut outs withthe folding bar and contacting at least three bridging portionscontemporaneously with the folding bar to maintain the folded edge afterthe web exits the folding wheel. The method further includes spanning atleast three cut outs with the folding bar and contacting at least fourbridging portions contemporaneously with the folding bar to maintain thefolded edge after the web exits the folding wheel.

In some embodiments, the web may further include a plurality ofabsorbent cores joined thereto, wherein the absorbent cores at leastpartially overlay the cut outs. In some embodiments, the method furtherincludes joining a first laminate web with a second laminate web. Insome embodiments, both the first and the second laminate webs comprisethe cut outs. In some embodiments, the web is directed to the foldingbar with a folding board to maintain the folded edge between the foldingbar and the folding board.

In another aspect, the present invention provides another method forfolding a web. The method includes providing a web to a first conveyor,the web comprising a series of cut outs, the series of cut outs definingbridging portions located between the cut outs. The method furtherincludes folding the web about a folding wheel to define a folded edge,wherein the folded edge extends through the series of cut outs. Themethod further includes transferring the web to a second conveyor, thefirst and second conveyors defining an included angle of 15 to 40degrees. The method further includes folding the web about a folding barto maintain the folded edge, and spanning at least one cut out with thefolding bar and contemporaneously contacting at least two bridgeportions to maintain the folded edge of the web about the folding bar.

In various embodiments, the method may further include spanning at leasttwo cut outs with the folding bar and contacting at least three bridgingportions with the folding bar to maintain the folded edge. The methodmay further include joining a plurality of absorbent cores to the web.The method may further include a first laminate web joined with a secondlaminate web wherein both of the laminate webs comprise the series ofcut outs. In various embodiments, the method may further includedirecting the web about the folding bar with a folding board to maintainthe folded edge between the folding bar and the folding board.

The above-mentioned and other aspects of the present invention willbecome more apparent, and the invention itself will be better understoodby reference to the drawings and the following description of thedrawings.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 representatively illustrates a side schematic view of anexemplary apparatus of the present invention;

FIG. 2 representatively illustrates a top schematic view of theapparatus of FIG. 1;

FIG. 3 representatively illustrates a perspective view of an exemplarymethod and apparatus of the present invention;

FIG. 4 representatively illustrates a top view of the method andapparatus of FIG. 3;

FIG. 5 representatively illustrates an exemplary garment manufacturingprocess incorporating one aspect of the method and apparatus of thepresent invention;

FIG. 5A representatively illustrates a cross sectional view of themethod and apparatus of FIG. 5 taken along the line 5A-5A;

FIG. 5B representatively illustrates a cross sectional view of themethod and apparatus of FIG. 5 taken along the line 5B-5B;

FIG. 6 representatively illustrates a detailed view of the portion ofthe method and apparatus of FIG. 5 designated by box 6;

FIG. 7 representatively illustrates a top view of the method andapparatus of FIG. 6;

FIGS. 7A, 7B, 7C, and 7D representatively illustrate cross sectionalviews of the method and apparatus of FIG. 7 taken along the lines 7A-7A,7B-7B, 7C-7C, and 7D-7D respectively; and

FIG. 8 representatively illustrates an exemplary absorbent articlemanufactured in part by the method and apparatus of the presentinvention.

Corresponding reference characters indicate corresponding partsthroughout the drawings.

Definitions

Within the context of this specification, each term or phrase below willinclude the following meaning or meanings.

“Attach” and its derivatives refer to the joining, adhering, connecting,bonding, sewing together, or the like, of two elements. Two elementswill be considered to be attached together when they are integral withone another or attached directly to one another or indirectly to oneanother, such as when each is directly attached to intermediateelements. “Attach” and its derivatives include permanent, releasable, orrefastenable attachment. In addition, the attachment can be completedeither during the manufacturing process or by the end user.

“Bond” and its derivatives refer to the joining, adhering, connecting,attaching, sewing together, or the like, of two elements. Two elementswill be considered to be bonded together when they are bonded directlyto one another or indirectly to one another, such as when each isdirectly bonded to intermediate elements. “Bond” and its derivativesinclude permanent, releasable, or refastenable bonding.

“Boxer shorts” or “Shorts” refers to pants, trunks, briefs, and thelike, and include garments that may be relatively loose fitting or snugat the leg area.

“Complex web” refers to a continuous web of material having one or morelayers or “plies” wherein the one or more layers may be joined at leastpartially together by any suitable means. A complex web may furtherinclude a plurality of discrete absorbent assemblies attachedintermittently thereto. A complex web may further include one or morecut away portions. A complex web may include two layers of materialbonded together at a crotch seam surrounding a crotch opening with aplurality of discrete absorbent assemblies attached thereto.

“Connect” and its derivatives refer to the joining, adhering, bonding,attaching, sewing together, or the like, of two elements. Two elementswill be considered to be connected together when they are connecteddirectly to one another or indirectly to one another, such as when eachis directly connected to intermediate elements. “Connect” and itsderivatives include permanent, releasable, or refastenable connection.In addition, the connecting can be completed either during themanufacturing process or by the end user.

“Disposable” refers to articles which are designed to be discarded aftera limited use rather than being laundered or otherwise restored forreuse.

The terms “disposed on,” “disposed along,” or “disposed toward” andvariations thereof are intended to mean that one element can be integralwith another element, or that one element can be a separate structurebonded to or placed with or placed near another element.

“Downstream” refers to the positioning of one element or event furtherin the direction of material travel relative to another element or eventin a process.

“Elastic,” “elasticized,” “elasticity,” and “elastomeric” mean thatproperty of a material or composite by virtue of which it tends torecover its original size and shape after removal of a force causing adeformation. Suitably, an elastic material or composite can be elongatedby at least 25 percent (to 125 percent) of its relaxed length and willrecover, upon release of the applied force, at least 10 percent of itselongation. Desirably an elastic material or composite may be elongatedby at least 100 percent (to 200 percent), more desirably by at least 300percent (to 400 percent), of its relaxed length and recover, uponrelease of an applied force, at least 50 percent of its elongation.

“Fabrics” is used to refer to all woven, knitted and nonwoven fibrouswebs.

“Front-to-back crotch seam” refers to a seam extending from the frontregion to the back region of a pant-style garment, through the crotchregion. The seam can join two separate pieces of material, or separateedges of a single piece of material.

“Garment shell” refers to those portions of the articles produced by theprocess of the present invention that are not part of the absorbentassembly.

“Hanging legs” refers to the characteristic of a garment intended to beworn about the lower torso where the garment includes material thatextends below the crotch of the garment and is intended to generallycover at least a portion of the leg of the wearer; the material may beloose fitting about the leg of the wearer, fit snugly about the leg ofthe wearer and/or may be elastic or non-elastic.

“Hydrophilic” describes fibers or the surfaces of fibers which arewetted by the aqueous liquids in contact with the fibers. The degree ofwetting of the materials can, in turn, be described in terms of thecontact angles and the surface tensions of the liquids and materialsinvolved. Equipment and techniques suitable for measuring thewettability of particular fiber materials or blends of fiber materialscan be provided by a Cahn SFA-222 Surface Force Analyzer System, or asubstantially equivalent system. When measured with this system, fibershaving contact angles less than 90 degrees are designated “wettable” orhydrophilic, while fibers having contact angles greater than 90 degreesare designated “nonwettable” or hydrophobic.

“Layer” when used in the singular can have the dual meaning of a singleelement or a plurality of elements.

“Liquid impermeable”, when used in describing a layer or multi-layerlaminate, means that a liquid, such as urine, will not pass through thelayer or laminate, under ordinary use conditions, in a directiongenerally perpendicular to the plane of the layer or laminate at thepoint of liquid contact.

“Machine direction” refers to the direction in which material travelsduring a production process, as opposed to “cross machine direction”which refers to the direction that is generally transverse andperpendicular to the machine direction.

“Nonwoven” and “nonwoven web” refer to materials and webs of materialthat are formed without the aid of a textile weaving or knittingprocess.

“Open Configuration” refers to the condition that the garment shell webis in before the formation of a waist opening and a pair of leg openingsin the article. The garment shell web may be manipulated, have portionsdirected in the machine direction or the cross machine direction, or maybe separated into individual garment chassis and still be in an openconfiguration, provided that the formation of the waist opening and theleg openings has not yet been completed.

“Overlap” refers to the condition where one element is positioned to beat least partially covering another element either directly orindirectly. It should be noted that one element may be beneath the otherelement and still be overlapping the other element.

“Pants” includes full length and short pants.

“Stretchable” means that a material can be stretched, without breaking,by at least 25 percent (to 125 percent of its initial (unstretched)length) in at least one direction, suitably by at least 100 percent (to200 percent of its initial length), desirably by at least 150 percent(to at least 250 percent of its initial length).

“Upstream” refers to the positioning of an element or event further inthe direction opposite to the direction of material travel relative toanother element or event in a process.

These terms may be defined with additional language in the remainingportions of the specification.

DETAILED DESCRIPTION

Referring now to FIGS. 1 and 2, an apparatus for folding a complex webis shown at reference numeral 202. FIG. 1 representatively illustrates aside perspective view of the apparatus 202. FIG. 2 representativelyillustrates a top perspective view of the apparatus 202. The apparatus202 has a machine direction 102, a cross machine direction 104, and anorthogonal direction 106. The apparatus 202 includes a first conveyor204 and a second conveyor 206. The first conveyor 204 and the secondconveyor 206 define an included angle 208 as illustrated in FIG. 1. Thefirst conveyor 204 and the second conveyor 206 may be generally alignedin the cross machine direction 104 as illustrated in FIG. 2. Theapparatus 202 further includes a folding wheel 210 and a folding bar212. In some embodiments, the apparatus 202 may further include afolding board 214.

The apparatus 202 can include any suitable web conveyors, such as, forexample, conveyor belts, vacuum drums, transport rolls, electromagneticsuspension conveyors, fluid suspension conveyors, or the like, andcombinations thereof. As representatively shown, the web conveyors 204and 206 can be provided by endless conveyor belts 205 and 207 disposedabout rollers 218. One or more of the rollers 218 may be driven by anysuitable means, such as, for example, an electric motor to move theconveyor belts 205 and 207 in the machine direction 102.

In a particular configuration of the invention, a vacuum suction box 220can be located below the first conveyor belt 205 and/or the secondconveyor belt 207 to assist in transporting a web through the apparatus202. The vacuum boxes 220 may open onto the belts 205 and 207 andsuction air out of the vacuum boxes to draw air flow through theperforations in the conveyor belts 205 and 207. This air flow may inturn operate to draw the web to the conveyor belts 205 and 207. The airflow in conjunction with the moving conveyor belts 205 and 207 may beconfigured to transport the web through the apparatus 202.

The first conveyor 204 and the second conveyor 206 define an includedangle 208 as illustrated in FIG. 1. The included angle 208 can suitablyrange from 0 to 50 degrees, 10 to 45 degrees, and 15 to 40 degrees.

The folding wheel 210 may be positioned proximate both the firstconveyor 202 and the second conveyor 204 as illustrated in FIGS. 1 and2. The folding wheel 210 may be rotatably mounted to a shaft 211. Theshaft 211 may extend through the folding wheel 210 and may be supportedon both ends or may be cantilevered from one end as illustrated in FIG.2. The shaft 211 and the folding wheel 210 may be operatively rotated byany suitable drive mechanism, such as an electrical motor (not shown).In some embodiments, the shaft 211 and/or the folding wheel 210 may notbe driven and may be allowed to freely rotate.

The folding wheel 210 defines a folding wheel edge 216. The foldingwheel 210 and the folding wheel edge 216 may be positioned in the crossmachine direction 104 at any suitable position relative to the firstconveyor 204 and the second conveyor 206. As illustrated in FIG. 2, thefolding wheel edge 216 may be positioned approximately at the crossdirectional 104 centerline of the first conveyor 204 and the secondconveyor 206.

The folding bar 212 is cantilevered over the second conveyor 206 and isgenerally parallel to the second conveyor belt 207 and is supported byany suitable means such that a continuous web may pass between thefolding bar 212 and the second conveyor 206 and may be folded over thefolding bar 212. In some embodiments, the folding bar 212 may be joinedto non-rotating bracketry associated with the folding wheel 210. In someembodiments, the folding bar 212 may be shaped like the number “7” andmay extend approximately to the point on the folding wheel 210 closestto the second conveyor belt 207 as illustrated in FIG. 1.

In various embodiments, the apparatus 202 may further include one ormore folding boards 214. In the illustrated embodiment of FIGS. 1 and 2,the folding board 214 is positioned in a generally facing relation withthe second conveyor belt 207. The folding board 214 may be positioned atan angle as compared with the second conveyor belt 207. The foldingboard 214 may be positioned such that the folding bar 212 extendsbetween the folding board 214 and the second conveyor belt 207.

Referring now to FIGS. 3 and 4, the apparatus 202 of FIGS. 1 and 2 isillustrated as part of a method 230 for folding a web 232. FIG. 3representatively illustrates a side perspective view of the method 230whereas FIG. 4 representatively illustrates the method 230 of FIG. 3from a top view. The method 230 includes providing a web 232 to thefirst conveyor 204 and passing the web 232 about the folding wheel 210.The web 232 folds about the folding wheel edge 216 to define a foldededge 234 in the web 232. The method 230 further includes transferringthe web 232 to the second conveyor 206 wherein the first conveyor 204and the second conveyor 206 define an included angle 208 of 15 to 40degrees. Finally, the method 230 includes folding the folded edge 234 ofthe web 232 about the folding bar 212 to maintain the folded edge 234 asthe web is moved away from the folding wheel 210.

In various embodiments, the method 230 may include folding a web 230having a plurality of cut away portions 236 wherein the folded edge 234extends through the cut away portions 236 as representativelyillustrated in FIGS. 3 and 4. In some embodiments the cut away portions236 have a repeat length 238. The repeat length 238 is the length fromthe front of a first cut away portion 236 to the front of a secondconsecutive cut away portion 236 as illustrated in FIG. 4. In someembodiments, the method 230 includes maintaining the folded edge 234 ofthe web 232 about the folding bar 212 for a distance of at least 2, atleast 3, at least 4, or at least 5 times the repeat length 238.

The web 230 of FIGS. 3 and 4 includes a bridging portion 180 spanningbetween the cut out portions 236. The folding bar 212 of the presentinvention allows the folded edge 234 to be maintained even in sectionsincluding a cut away portion 236 by maintaining contact with thebridging portions 180. In other words, the web 230 folds about thefolding wheel edge 216 to define the folded edge 234 when a bridgingportion 180 is in contact with the folding wheel 210. When a cut awayportion 236 moves past the folding wheel edge 216, the folded edge 216is not lost because the folding bar 212 extends from the folding wheel210 and maintains contact with one or more of the bridging portions 180.As will be apparent to one skilled in the art, the folded edge 234 istherefore only truly an “edge” in the bridging portions 180 and merelydefines the position of the web 230 relative to the folding wheel edge216 in the cut away portions 236.

In some embodiments, the method 230 further includes folding a web 232having a plurality of absorbent cores joined thereto. In someembodiments, the absorbent cores may at least partially overlay the cutaway portions 236.

In some embodiments, the method 230 includes folding a web 232 whereinthe web 232 includes a first web attached with a second web to form alaminate web. One of more of the laminate webs may include cut awayportions.

In some embodiments, the method 230 includes directing the web 232 aboutthe folding bar 212 with a folding board 214 to maintain the folded edge234.

The method and apparatus of the present invention may be utilized in anysuitable converting operation. One particularly useful applicationincludes folding a complex web as part of a garment manufacturingoperation. For example, the present method and apparatus may be suitablefor folding the complex web described in U.S. Application 2005/0241748,entitled “Process For Making A Garment Including An Absorbent Assembly,”published on Nov. 3, 2005 to Allen, the entirety of which isincorporated herein by reference to the extent it is consistent (i.e.,not in conflict) herewith.

Referring now to FIG. 5, a process for making garments to be worn aboutthe lower torso is shown in its entirety at reference numeral 100 andincludes the method and apparatus described above. The process 100 willbe described in terms of making boxer shorts, or shorts 10, but itshould be readily recognized that the process of the present inventionmay be equally applicable with pants, trunks, briefs, and other garmentsthat may be worn about the lower torso and having a waist opening, apair of leg openings, and optionally a pair of hanging legs. The shorts10 of the present invention can include a garment shell and may furtherinclude an absorbent assembly 60, as will be described in greater detailbelow. Such garments and a process for making them, are described inU.S. Pat. No. 6,192,521 issued Feb. 27, 2001 to Alberts, et al., thedisclosure of which is incorporated herein by reference to the extent itis consistent (i.e., not in conflict) herewith.

The process 100 of the various aspects of the present invention definesa machine direction indicated at the arrow marked 102, and a crossmachine direction indicated at the arrow marked 104 that isperpendicular to the machine direction 102. The process 100 also definesan orthogonal direction, indicated at the arrow marked 106 that isperpendicular to the plane created by the machine direction 102 and thecross machine direction 104. Further, the process also defines a processcenterline 108 extending in the machine direction 102.

In some aspects, the process 100 is represented with the orthogonaldirection 106 being generally vertical in orientation. Nonetheless, ascan be readily appreciated by those of skill in the art, the orthogonaldirection 106 of the present invention may also be generally horizontalin orientation or may otherwise be oriented and still be within thescope of the present invention.

The process includes transporting a garment shell web 140 in the machinedirection 102. The garment shell web 140 can include any combination ofmaterials that together provide the garment shell of the shorts 10. Thegarment shell web 140 may be provided by a single web or a plurality ofwebs. For example, the garment shell web 140 can include a first web 110and a second web 120. Thus, the first web 110 and the second web 120 maybe provided and transported in the machine direction 102 to provide thegarment shell web 140. In addition, the garment shell web 140 defines apair of opposed garment shell web side edges 142 that extendsubstantially in the machine direction 102 and a garment shell web width144 in the cross machine direction 104.

In yet another alternative, it may be noted that the first web 110 andthe second web 120 may be provided by separate webs or may alternativelybe provided by a single web that is folded about the machine direction102 and then subsequently separated (not shown). As representativelyillustrated in FIG. 5, the webs 110 and 120 can be provided in asubstantially superposed relationship with each other.

The first web 110 of the garment shell web 140 defines a first web firstedge 112 and a first web second edge 114 that is opposite the first webfirst edge 112, and a first web interior 115 located within the firstweb first edge 112 and the first web second edge 114. The first web 110also defines a first web inner surface 116 that is in facingrelationship with the second web 120, and a first web outer surface 118that is opposite the first web inner surface 116.

The second web 120 of the garment shell web 140 defines a second webfirst edge 122 and a second web second edge 124 that is opposite thesecond web first edge 122, and a second web interior 125 that is locatedwithin the second web first edge 122 and the second web second edge 124.The second web 120 also defines a second web inner surface 126 that isin facing relationship with the first web 110, and a second web outersurface 128 that is opposite the second web inner surface 126.

As representatively illustrated in FIG. 5, the webs 110 and 120 may beprovided in at least a partially facing relationship, and may be in asubstantially completely facing relationship. For example, the secondweb inner surface 126 may be in at least a partially facing relationshipwith the first web inner surface 116. It should be noted that the firstand second web inner and outer surfaces 116, 118, 126, and 128 need notcorrespond to a body facing surface 28 and an exterior surface 30 of aresultant garment when the garment is produced.

The process 100 is illustrated in FIG. 5 as being configured to have thegarment shell web 140 pass through the process 100 in a generallyhorizontal orientation. Nonetheless, as can be readily appreciated bythose of skill in the art, the process 100 may be configured to have thegarment shell web 140 pass through the process 100 in a generallyvertical or other orientation and still be within the scope of thepresent invention. Suitably, the garment shell web 140 can be initiallyprovided to the process 100 in a generally planar position. For example,in configurations where the garment shell web 140 is provided by a firstweb 110 and a second web 120, the webs 110 and 120 may initially beprovided to the process 100 with the web edges 112, 114 and 122, 124 ina spaced relationship.

The garment shell web 140 may be any suitable fabric to provide theshorts 10. In particular, the garment shell web 140 may suitably be ofmaterials which are comfortable against the skin and non-irritating.Since it is contemplated that the shorts 10 can be either disposable ordurable (i.e., launderable), both nonwoven and woven materials arecontemplated for the garment shell web 140. For example, the garmentshell web 140 can be selected from a wide variety of materials,including elastic, stretchable, or nonstretchable materials. Any othertype of nonwoven laminate or woven or knitted fabric known to thoseskilled in the art can also be used. The garment shell web 140 can be asingle layer of material or a multi-layered laminate structure.Moreover, as discussed above, the garment shell web 140 may be providedby a plurality of webs (e.g., the webs 110 and 120).

The garment shell web 140 may be provided to and transported through theprocess 100 by various methods as are known in the art. For example, thegarment shell web 140 may be unwound and drawn through the process 100via driven rolls, belt conveyors, chain conveyors, and the like, orcombinations thereof (not shown).

In the various aspects of the process 100 of the present invention, thegarment shell web 140 may also include a crotch seam 56. The garmentshell web 140 may be provided to the process 100 with the crotch seam 56already in place, or the crotch seam 56 may by incorporated in thegarment shell web 140 in the course of the process 100.

For example, as representatively illustrated in FIG. 5, the garmentshell web 140 includes webs 110 and 120, which may be attached to oneanother to provide a crotch seam 56. In particular aspects, spacedportions of the garment shell web 140 may be attached to one another atselected locations to provide a plurality of crotch seams 56. The seams56 may be substantially continuous, or may be provided by a series ofintermittent bonds. The crotch seam 56 may be of various shapes toproduce the desired result. For example, the crotch seam 56 may begenerally rectilinear, curvilinear (for example, circular or oval),generally “D” shaped, or generally “U” shaped. In particular aspects,the crotch seam 56 may be at least partially curvilinear to provide agarment with improved fit and comfort.

The crotch seam 56 may be imparted to the garment shell web 140 by abonding device 132 in various ways as are known in the art. For example,the crotch seam 56 may be formed by bonding portions of the garmentshell web 140 (e.g., bonding the first web 110 to the second web 120) asit travels in the machine direction 102. This bonding can beaccomplished by using ultrasonic, pressure, or thermal bonding wheelsrotating in a facing relationship to form the crotch seam 56. Forexample, an anvil wheel and a horn wheel defining a nip can be used toform the crotch seam 56. Alternatively, any suitable bonding methodknown in the art can be used, such as adhesives, sewing or the like.

The process 100 of the present invention may further include providing acrotch opening 54 in the garment shell web 140. For example, portions ofthe garment shell web 140 may be removed by the process 100 in order toprovide the crotch opening 54. Alternatively, the garment shell web 140may be provided to the process 100 with a crotch opening 54 or a seriesof crotch openings 54 already in place. In a particular aspect, theprocess 100 of the present invention may include selectively removingportions of the garment shell web 140 to provide a series of spacedcrotch openings 54. Suitably, the boundaries of the crotch opening 54may be located completely within the garment shell web side edges 142.The crotch openings 54 may be separated by bridging portions 180.

In a particular aspect, as representatively illustrated in FIG. 5, thegarment shell web 140 is provided by webs 110 and 120. The process 100may include selectively removing a portion of the first web 110 todefine a first web removal portion 119. In addition, the process 100 ofthe present invention may include selectively removing a portion of thesecond web 120 to define a second web removal portion 129. As mentionedabove, the portions of the webs 110 and 120 that are removed 119 and 129can be located within the first web interior 115 and the second webinterior 125. Suitably, when the garment shell web 140 includes multiplelayers of material, the portions that are removed 119 and 129 aregenerally aligned to define a crotch opening 54 that passes through thegarment shell web 140. For instance, as illustrated in FIG. 5, theportions of the webs 110 and 120 that are removed 119 and 129 aregenerally in alignment with each other, and as such, define a commoncrotch opening 54 within the first web interior 115 and within thesecond web interior 125.

The crotch opening 54 may be any suitable shape to provide a crotch gapin the garment shell of the shorts 10. For example, the crotch opening54 may be rectangular, oval shaped, curvilinear, rectilinear, and thelike, or combinations thereof. In particular, as representativelyillustrated in FIG. 5, the crotch opening 54 may be elongated in themachine direction 102 and may be at least partially curvilinear. Thecrotch opening 54 can define a pair of side edges 57 that generallyextend in the machine direction 102. The crotch opening 54 may alsodefine an opening centerline 55 extending in the machine direction 102.

Further, the crotch opening 54 may also define a pair of end edges. Forinstance, the crotch opening 54 can define an upstream end edge 58 and adownstream end edge 59 opposite the upstream opening end edge 58, eachgenerally extending in the cross machine direction 104. Suitably, atleast one of the upstream or downstream end edges 58 and 59 arecurvilinear, and still more suitably, both of the end edges 58 and 59are curvilinear. Alternatively, one of the upstream or downstreamopening end edges 58 and 59 may be substantially parallel with the crossmachine direction 104 while the other opening end edge 58 or 59 iscurvilinear.

The crotch opening 54 may suitably be located proximate the processcenterline 108. For example, the opening centerline 55 may be adjacentand parallel to the process centerline 108. In particular embodiments,the opening centerline 55 may overlap the process centerline 108.Alternatively, the opening centerline 55 may be offset in the crossmachine direction 104 from the process centerline 108. In such aconfiguration, the shorts 10 may be tailored to provide a greater amountof crotch depth in a front region 22 of the shorts 10 or in a backregion 24 of the shorts 10.

The providing of the crotch opening 54 may be accomplished by variousmethods as are known in the art. For example, a portion or portions ofthe garment shell web 140 may be removed by a cutting device 134 such ascutting rolls, a die cutting assembly, a water cutting device or anultrasonic cutter, or combinations thereof. Alternatively, othersuitable cutting methods known in the art can be used. In yet anotheralternative, portions of the garment shell web 140 may be perforated andmay be removed subsequently in the process 100 to provide the crotchopening 54.

It should be noted that the step of providing the crotch seam 56 and thestep of providing of the crotch opening 54 need not occur in aparticular order, and moreover, need not happen sequentially. Forexample, the step of providing of a crotch opening 54 may occur prior tothe formation of a crotch seam 56 or the step of forming a crotch seam56 may occur prior to providing the crotch opening 54. In yet anotheralternative, the formation of the crotch seam 56 may occur at the sametime as the formation of the crotch opening 54. For instance, this maybe accomplished by utilizing an ultrasonic bonder that is also capableof cutting.

As can be readily appreciated, the crotch opening 54 and the crotch seam56 may be located as necessary in the garment shell web 140, and maysuitably be positioned proximate one another in the garment shell web140, or be otherwise associated. For example, as representativelyillustrated in FIG. 5, the crotch seam 56 may be located adjacent thecrotch opening 54. In addition, as representatively illustrated in FIG.5, the crotch seam 56 may partially or fully circumscribe the crotchopening 54.

In addition, and as will be discussed in greater detail below, thegarment shell web may be separated into individual garment chassis 150.This separation may occur such that a crotch seam 56 and an associatedcrotch opening 54 may be divided by the step of separation into a pairof associated crotch seams 56 and crotch openings 54, with one crotchseam 56 and one crotch opening 54 being associated with the garmentchassis 150.

In the various aspects of the present invention, the process 100 mayinclude disposing an absorbent assembly 60 on the garment shell web 140.The absorbent assembly 60 can be any structure which is generallycompressible, conformable, non-irritating to the skin, and capable ofabsorbing and retaining liquids and certain body wastes. The absorbentassembly 60 can be manufactured in a wide variety of sizes and shapes,from a wide variety of liquid absorbent materials commonly used in theart, and may be stretchable, non-stretchable, or elastic. For example,the absorbent assembly 60 can suitably include a matrix of hydrophilicfibers, such as a web of cellulosic fluff, mixed with particles of ahigh-absorbency material commonly known as superabsorbent material.

For example, as representatively illustrated in FIG. 5, an absorbentassembly 60 may be disposed on the garment shell web 140 proximate thecrotch opening 54. In particular, where the garment shell web 140 isprovided by a first and second web 110 and 120, the absorbent assembly60 may be disposed on at least one of the webs 110 and 120. For example,as representatively illustrated in FIG. 5, the absorbent assembly 60 maysuitably be disposed on the first web 110 proximate the crotch opening54.

The absorbent assembly 60 may be disposed on the garment shell web 140at various points throughout the process 100 as can be appreciated byone of skill in the art. Suitably, the absorbent assembly 60 may bedisposed on the garment shell web 140 while the garment shell web is inan open configuration. That is, the garment shell web 140 may be in acompletely planar position and still be in an open configuration.Further, as will be discussed in greater detail below, portions of thegarment shell web 140 may be directed in the machine direction 102 orthe cross machine direction 104, and the garment shell web 140 is stillin the open configuration. Thus, provided that portions of the garmentshell web 140 have not been attached together to form a waist opening 50and a pair of leg openings 52, the garment shell web 140 is in an openconfiguration. In a particular aspect, and as representativelyillustrated in FIG. 5, the garment shell web 140 is provided by a firstweb and a second web 110 and 120. In such a configuration, the absorbentassembly 60 can be disposed on at least one of the webs 110 and 120while the edges 112, 114 and 122, 124 of at least one of the webs 110and 120 are in a spaced relationship, and therefore the garment shellweb 140 is in an open configuration.

The absorbent assembly 60 of the present invention may also define anabsorbent assembly centerline 61 that, upon being disposed upon thegarment shell web 140, extends in the machine direction 102. Suitably,when an absorbent assembly 60 is disposed on the garment shell web 140,the absorbent assembly centerline 61 may be located proximate one of theopening side edges 57 (FIG. 5). In such an arrangement, the absorbentassembly 60 may overlap at least a portion of the crotch opening 54.More suitably, the absorbent assembly centerline 61 may be locatedadjacent one of the opening side edges 57 and be parallel or generallyparallel with the process centerline 108.

The absorbent assembly 60 may be arranged on the garment shell web 140in a number of ways, as may be influenced by the configuration of theabsorbent assembly 60 and the style of the shorts 10. For example, asrepresentatively illustrated in FIG. 5, a single absorbent assembly 60may be associated with each crotch opening 54 prior to the garment shellweb 140 being separated into individual garment chassis 150. In such aconfiguration, upon separation of the garment shell web 140 intoindividual garment chassis 150, both the opening 54 and the absorbentassembly 60 may also be divided into a pair of openings 54 and a pair ofabsorbent assemblies 60, with one of the pair of crotch openings 54 andone of the pair of absorbent assemblies 60 being associated with thegarment chassis 150.

The process 100 of the various aspects of the present invention may alsoinclude directing at least a portion of the garment shell web 140 in thecross machine direction 104 to define a folded portion. Moreover, thefolded portion may define an overlapping portion, such as a first weboverlapping portion and/or a second web overlapping portion. As will bediscussed in greater detail below, the directing of at least a portionof the garment shell web 140 in the cross machine direction 104 mayoccur before or after the garment shell web 140 is separated intoindividual garment chassis 150.

For example, in one aspect and as representatively illustrated in FIG.5A, the second web 120 may be directed in the cross machine direction104 to define a folded portion. FIG. 5A representatively illustrates across sectional view of the method and apparatus of FIG. 5 taken alongthe line 5A-5A. Similarly, FIG. 5B representatively illustrates a crosssectional view of the method and apparatus of FIG. 5 taken along theline 5B-5B. Suitably, a portion of the second web 120 proximate toeither the second web first edge 122 or the second web second edge 124is directed in the cross machine direction 104 toward the processcenterline 108 and the opposing edge 122 or 124 such that the foldedportion at least partially overlaps the crotch opening 54 to define asecond web overlapping portion 160. For example, the second weboverlapping portion 160 may overlap the entire crotch opening 54, asillustrated in FIG. 5B, or alternatively the second web overlappingportion 160 may overlap only part of the crotch opening 54. In yetanother alternative, a portion of the second web 120 may be directed inthe cross machine direction 104 such that the second web overlappingportion 160 overlaps substantially the entire crotch opening 54 and thesecond web first edge 122 is substantially adjacent the second websecond edge 124.

Thus, to direct a portion of the second web 120 in the cross machinedirection 104, the second web 120 may be folded upon itself startingfrom the second web first edge 122. As a result, that portion of thesecond web 120 may be folded upon itself proximate the crotch seam 56toward the process centerline 108 and the second web second edge 124 anddesirably at least partially overlaps the crotch opening 54.Alternatively, in another aspect, a portion of the second web 120 may befolded upon itself starting from the second web second edge 124 asillustrated in FIGS. 5A and 5B. As a result, that portion of the secondweb 120 is folded upon itself proximate the crotch seam 56 toward theprocess centerline 108 and the second web first edge 122 and desirablyat least partially overlaps the crotch opening 54.

To provide the second web overlapping portion 160, the second web 120 issuitably directed in the cross machine direction 104 and folded uponitself from the second web edge 122 or 124 that is closer to theintended location of the absorbent assembly 60 (whether it has yet beendisposed on the webs 110 or 120 or not), relative to the other secondweb edge 122 or 124.

For example, as representatively illustrated in FIG. 5A, the second websecond edge 124 is proximate the location of the absorbent assembly 60(disposed on the first web 110). Accordingly, the second web second edge124 is included in the portion of the second web 120 that is directed inthe cross machine direction 104 toward the process centerline 108 andthe second web first edge 122 to at least partially overlap the crotchopening 54.

The directing of the second web 120 in the cross machine direction 104to define a folded portion can occur either before or after theabsorbent assembly 60 is disposed upon the webs 110 and 120. Inarrangements where the directing of the second web 120 occurs after theabsorbent assembly 60 is disposed on one of the webs 110 or 120, thesecond web overlapping portion 160 may also overlap at least a portionof the absorbent assembly 60. That is, as representatively illustratedin FIGS. 5B and 7A, the portion of the second web 120 directed in thecross machine direction 104 may overlap the crotch opening 54 andoverlap the absorbent assembly 60 to define a folded portion and thesecond web overlapping portion 160.

Further, the process 100 of the various aspects of the present inventionmay also include directing at least a portion of the first web 110 inthe cross machine direction 104 to define a folded portion asrepresentatively illustrated in FIG. 6. FIG. 6 representativelyillustrates, in greater detail, the portion of the method and apparatusof FIG. 5 circumscribed by box 6. FIG. 7 representatively illustrates atop view of the method and apparatus of FIG. 6. FIGS. 7A, 7B, 7C, and 7Drepresentatively illustrate cross sectional views of the method andapparatus of FIG. 7 taken along the lines 7A-7A, 7B-7B, 7C-7C, and 7D-7Drespectively.

Suitably, the first web 110 is directed in the cross machine direction104 such that the folded portion of the first web 110 at least partiallyoverlaps the absorbent assembly 60 to define a first web overlappingportion 170. For example, the first web overlapping portion 170 mayoverlap the absorbent assembly 60 entirely, or alternatively, the firstweb overlapping portion 170 may overlap a portion of the absorbentassembly 60. In addition, subsequent to the directing of the first web110, a portion of the absorbent assembly 60 may be overlapped by thefirst web overlapping portion 170 and a portion of the second web 120 asrepresentatively illustrated in FIG. 7B.

In particular aspects, portions of the first web 110 proximate to eitherthe first web first edge 112 or the first web second edge 114 may bedirected in the cross machine direction 104 toward the processcenterline 108 and the opposing edge 112 or 114. Thus, the first web 110may be folded upon itself from the first web first edge 112 or the firstweb second edge 114. As a result, in one aspect, the portion of thefirst web 110 that is proximate the first web first edge 112 can bedirected in the cross machine direction 104 toward the processcenterline 108 and the first web second edge 114, and at least partiallyoverlap the absorbent assembly 60. Further, the portion of the first web110 that is proximate the first web first edge 112 can be directed inthe cross machine direction 104 such that the first web first edge 112is substantially adjacent to the first web second edge 114 asillustrated in FIG. 7B.

Alternatively, in another aspect, the portion of the first web 110 thatis proximate the first web second edge 114 can be directed in the crossmachine direction 104 toward the process centerline 108 and the firstweb first edge 112, and at least partially overlap the absorbentassembly 60. Further, the portion of the first web 110 that is proximatethe first web second edge 114 can be directed in the cross machinedirection 104 such that the first web second edge 114 is substantiallyadjacent to the first web first edge 112.

As discussed previously, the various webs are moved about the foldededge 234 as representatively illustrated in FIGS. 6 and 7. The foldededge 234 is defined by the folding wheel 210 and in particular thefolding wheel edge 216. As the web 232 moves past the folding wheel edge216 the web 232 is folded along the folded edge 234. However, as thecrotch openings 54 pass the folding wheel edge 216 there is no materialto define and maintain the folded edge 234. In order to prevent the lossof the folded edge 234, the folding bar 212 extends from the foldingwheel 210 and essentially “extends” the folding wheel edge 216 in themachine direction 102 a sufficient distance to span at least one crotchopening 54. By “extending” the folding wheel edge 216 via the foldingbar 212, the bridging portions 180 of the web 232 remain in contact withthe folding bar 212. Therefore, even when a crotch opening 54 passes thefolding wheel edge 216, portions of the folded edge 234 remain incontact with the folding bar 212 via the bridging portions 180 asrepresentatively illustrated in FIGS. 7 and 7C.

The folding bar 214 may extend any suitable distance beyond the foldingwheel edge 216. As described previously, the web 232 defines amultiplicity of repeat lengths 238. The folding bar 214 may extend one,two, three, or more repeat lengths 238 such that the folding bar 214 maybe in contemporaneous contact with one, two, three, or more bridgingportions 180. As such, the folding bar 214 may maintain the folded edge234 until the web 232 is completely folded as illustrated in FIG. 7C.FIG. 7C provides a cross sectional view of a bridging portion 180wherein the folded edge 234 contacts the folding bar 212 to maintain thefolded edge 234 even as a crotch opening 54 passes the folding wheeledge 216.

In particular aspects, in order to define a folded portion and providethe first web overlapping portion 170, the first web 110 may suitably bedirected in the cross machine direction 104 and folded upon itself fromthe first web edge 112 or 114 that is distant from the absorbentassembly 60 relative to the opposing edge 112 or 114. For example, asillustrated in FIG. 7A, the first web first edge 112 is distant from thelocation of the absorbent assembly 60 (disposed on the first web 110)relative to the first web second edge 114 and is included in the portionof the second web 120 that is directed in the cross machine direction104 to partially overlap the absorbent assembly 60. Moreover, the firstweb first edge 112 is placed substantially adjacent said first websecond edge 114 as representatively illustrated in FIGS. 7B and 7C. Inaddition, the opening side edges 57 may become substantially aligned inthe orthogonal direction 106 as a result, as representativelyillustrated in FIG. 7B.

Referring now to FIGS. 7B and 7C, the second web first edge 122 isdirected in the cross machine direction 104 such that the second webfirst edge 122 is substantially aligned with the second web second edge124 as representatively illustrated in FIG. 7D.

The directing of the first web 110 and the second web 120 need nothappen in any particular order. For example, the directing of the firstweb 110 may occur before the directing of the second web 120, or viceversa. In addition, as indicated above, the directing of the first web110 and the second web 120 may occur before or after the garment shellweb 140 is separated into individual garment chassis 150. Moreover, thedirecting of the webs may, but need not occur consecutively; forexample, intervening steps may occur between the directing of the webs110 and 120. Nonetheless, in configurations where the steps of directingthe first web 110 and the second web 120 have occurred in the process100, the edges 112, 114, 122, and 124 of the webs 110 and 120 can becomesubstantially aligned as a result.

For example, as representatively illustrated in FIG. 7D, upon thedirecting of the first web 110 and the second web 120 in the crossmachine direction 104 as described above, the first web first edge 112and the first web second edge 114 can be arranged to be substantiallyadjacent each other. Similarly, following the directing of the first web110 and the second web 120 in the cross machine direction 104 asdescribed above, the second web first edge 122 and the second web secondedge 124 may be arranged to be substantially adjacent each other.

The process 100 of the present invention may also include the step ofattaching a portion of the absorbent assembly 60 to the garment shellweb 140 by a variety of methods as are known in the art. For example,the absorbent assembly 60 may be attached by adhesives, ultrasonicbonding, pressure bonding, sewing, and the like, or combinationsthereof.

As mentioned above, the process 100 may further include the step ofseparating the garment shell web 140 into a plurality of discreteindividual sections or garment chassis 150. The separation of thegarment shell web 140 into individual garment chassis 150 may occur atvarious points in the process 100. For example, the separation before orafter the crotch opening 54 is provided in the garment shell web 140,before or after disposing the absorbent assembly 60 on the garment shellweb 140, and before or after portions of the garment shell web 140 aredirected in the cross machine direction 104.

The garment shell web 140 may be separated into garment chassis 150 in avariety of ways as are known in the art. For example, the process 100may include a separation device 138 that cuts the garment shell web 140into individual garment chassis 150. Specifically the separation device138 may be a die cutter, a water cutter, a rotary cutter, an ultrasoniccutter, or the like.

Portions of the garment shell web 140 may be arranged and attachedtogether to form a waist opening and a pair of leg openings 52 and toprovide the shorts 10. For example, portions of the webs 110 and 120 maybe attached together as representatively illustrated in FIG. 5. Inparticular, the first web first edge 112 may be attached to the firstweb second edge 114. Similarly, the second web first edge 122 may beattached to the second web second edge 124. Accordingly, shorts 10 witha waist opening 50, a pair of leg openings 52, and optionally a pair ofhanging legs 80 may be provided by the process 100. In addition, in sucha configuration, upon attaching the web edges 112, 114, 122, and 124together, the webs 110 and 120 may define a garment web width 146 in thecross machine direction 104 that is less than the garment shell webwidth 144.

In a particular aspect, the attaching of the first web first edge 112 tothe first web second edge 114 and the second web first edge 122 to thesecond web second edge 124 can form a pair of side seams 82. The sideseams 82 can take any number of forms, including both refastenable andnon-refastenable seams as is known in the art.

Optionally, the process 100 may be configured to provide the shorts 10such that the webs 110 and 120 may be attached together at a differenttime and/or location in order to form a pair of side seams 82 and awaist opening 50 and a pair of leg openings 52. That is, the process 100may be configured to provide an intermediate garment element where theattaching of the first web first edge 112 to the first web second edge114 and the attaching of the second web first edge 122 to the second websecond edge 124 are completed at another location or by the end user. Inparticular, the edges 112, 114, 122, and 124 may include complementaryfasteners, such as hook and loop fasteners, so that the webs 110 and 120may be attached together at a later time. In such an arrangement, theshorts 10 may, for example, be packaged with the edges 112, 114, 122,and 124 unattached so that the end user may attach the webs 110 and 120and obtain a customized fit.

The process 100 may further include attaching waist elastic material 70(FIG. 8) to the garment shell web 140. Suitably, the waist elasticmaterial may be attached to the garment shell web 140 while the garmentshell web is in an open configuration, or more suitably, in a planarconfiguration. For example, a portion of waist elastic material 70 maybe attached to the first web 110 and a separate portion of waist elasticmaterial 70 may be attached to the second web 120. The waist elasticmaterial 70 may be attached to the webs 110 and 120 in a variety oflocations. The waist elastic material 70 can be formed of any suitableelastic material including sheets, strands or ribbons of natural rubber,synthetic rubber, or thermoplastic elastomeric polymers.

The absorbent assembly 60 can also incorporate other materials that aredesigned primarily to receive, temporarily store, and/or transportliquid along the mutually facing surface with absorbent assembly 60,thereby maximizing the absorbent capacity of the absorbent assembly. Onesuitable material is referred to as a surge layer (not shown) andincludes a material having a basis weight of about 50 to about 120 gramsper square meter (gsm), and including a through-air-bonded-carded web ofa homogenous blend of 60 percent 3 denier type T-256 bicomponent fiberincluding a polyester core/polyethylene sheath and 40 percent 6 deniertype T-295 polyester fiber, both commercially available from KosaCorporation of Salisbury, N.C. U.S.A.

The absorbent assembly 60 may also include a liner material that isintended to face the wearer in use. The liner can be manufactured from awide selection of web materials, such as synthetic fibers (for example,polyester or polypropylene fibers), natural fibers (for example, wood orcotton fibers), a combination of natural and synthetic fibers, porousfoams, reticulated foams, apertured plastic films, or the like.

The absorbent assembly 60 may also include a suitable outercoverintended to face away from the body of the wearer in use. The outercoverdesirably comprises a material that is substantially liquid impermeable.The outercover can be a single layer of liquid impermeable material, ormay be a multi-layered laminate structure in which at least one of thelayers is liquid impermeable. The liquid impermeable material can alsobe configured to permit vapors to escape from the interior of theabsorbent body, while still preventing liquids from passing through theoutercover.

In particular embodiments, the absorbent assembly 60 is thin to providea slim, comfortable, non-bulky short 10. Any suitable thin absorbentassembly may be used, such as for example, the thin absorbent describedin WO 02/49565, published Jun. 27, 2002, by Sawyer et al., thedisclosure of which is incorporated herein by reference to the extent itis consistent (i.e., not in conflict) herewith.

The absorbent assembly 60 optionally may include a pair of containmentflaps 62 (FIGS. 5 and 6) which are configured to provide a barrier tothe transverse flow of body exudates. Suitable constructions andarrangements for the containment flaps 62 are generally well known tothose skilled in the art and are described in U.S. Pat. No. 4,704,116issued Nov. 3, 1987 to Enloe, which is incorporated herein by referenceto the extent that it is consistent (i.e., not in conflict) herewith.

To further enhance containment and/or absorption of body exudates, theabsorbent assembly 60 may also suitably include absorbent assembly waistelastics 68 and leg elastics 64, as are known to those skilled in theart (FIGS. 5 and 6). The absorbent assembly waist elastics 68 can beoperatively joined to the outercover and/or the liner along the opposingabsorbent assembly end edges 66. The leg elastics 64 can be operativelyjoined to the outercover and/or the liner along the opposite absorbentassembly side edges 67.

The absorbent assembly waist elastics 68 and the absorbent assembly legelastics 64 can be formed of any suitable elastic material. As is wellknown to those skilled in the art, suitable elastic materials includesheets, strands or ribbons of natural rubber, synthetic rubber, orthermoplastic elastomeric polymers. In one particular aspect, forexample, the leg elastics 64 can include a plurality of dry-spuncoalesced multifilament spandex elastomeric threads sold under the tradename LYCRA® and available from E. I. Du Pont de Nemours and Company,Wilmington, Del., U.S.A.

As representatively illustrated in FIG. 8, an embodiment of a short 10produced by the process 100 of the present invention can include a frontregion 22, a back region 24, a crotch region 26, a body facing surface28 which is configured to contact the wearer, and an exterior surface 30opposite the body facing surface 28 which is configured to face awayfrom the surface of the wearer's body. The short 10 also defines a pairof opposed waist edges, which are designated front waist edge 38 andback waist edge 39. The front region 22 is contiguous with the frontwaist edge 38, and the back region 24 is contiguous with the back waistedge 39. The front region 22 includes the portion of the short 10 which,when worn, is positioned on the front of the wearer while the backregion 24 includes the portion of the short 10 which, when worn, ispositioned on the back of the wearer. The crotch region 26 of the short10 includes the portion of the short which, when worn, is positionedbetween the legs of the wearer and covers the lower torso of the wearer.

As illustrated in FIG. 8, the front and back regions 22 and 24 arejoined together at side seams 82 and the left and right sides of theshort 10 are joined together at the crotch seam 56 to define athree-dimensional short configuration having a waist opening 50 and apair of hanging legs 80 with leg openings 52. In particular aspects, thecrotch seam 56 may follow a path which begins substantially at the frontwaist edge 38, extends through the crotch region 26, and terminatessubstantially at the back waist edge 39. In alterative embodiments, thecrotch seam 56 can follow a path which begins below the front waist edge38 on the front region 22 and terminates below the back waist edge 39 onthe back region 24. As is known in the art, the crotch seam 56 can be aninward butt seam or a lap seam (not shown). In the alternative, thecrotch seam 56 can be an outward butt seam.

In particular embodiments and as mentioned above, the short 10 caninclude an absorbent assembly 60. The absorbent assembly 60 can beattached to the short 10 at the front waist edge 38 and/or back waistedge 39, or at some point below the front waist edge 38 and/or the backwaist edge 39 in the front region 22 and back region 24. Alternativelyor additionally, the absorbent assembly 60 can be attached to the pant10 in the crotch region 26.

As various changes could be made in the above constructions and methods,without departing from the scope of the invention, it is intended thatall matter contained in the above description and shown in theaccompanying drawings shall be interpreted as illustrative and not in alimiting sense.

When introducing elements of the invention or the preferred aspect(s)thereof, the articles “a”, “an”, “the” and “said” are intended to meanthat there are one or more of the elements. The terms “comprising”,“including” and “having” are intended to be inclusive and mean thatthere may be additional elements other than the listed elements.

The invention claimed is:
 1. An apparatus for folding a web, comprising:a first conveyor, a second conveyor in close proximity to the firstconveyor, wherein the first and second conveyors define an includedangle of 15 to 40 degrees, a folding wheel aligned in close proximity toboth the first and second conveyors, and a folding bar extending aboveand generally parallel with the second conveyor.
 2. The apparatus ofclaim 1 further comprising a folding board proximate the second conveyorwherein the folding bar extends between the folding board and the secondconveyor.
 3. The apparatus of claim 1 wherein the folding wheelcomprises a shaft and the folding bar is connected to the shaft andcantilevered over the second conveyor.
 4. The apparatus of claim 3wherein the folding bar is shaped like the number “7”.
 5. The apparatusof claim 1 wherein at least one of the first and second conveyors is avacuum conveyor.